Dry net cleaning vacuum valve real-time monitoring system

Abstract

The invention discloses a real-time monitoring system for a dry net cleaning vacuum valve. The real-time monitoring system comprises a detection module, an alarm module, a feedback module, a program optimization module, a bracket structure and a data storage module, according to the invention, a dry net cleaning program is optimized by using off-machine limiting and self-processing of the fixing bracket, and the real-time use condition of the vacuum valve is efficiently detected without cost. And the conditions of wastage reduction and dry screen printing caused by blockage of the vacuum valve are effectively avoided, and the quality of finished paper is improved. Meanwhile, by adding real-time feedback and alarm functions on a DCS picture, the abnormity of the vacuum valve can be found in time, the failure rate is reduced, the workload of personnel is reduced, and the market competitiveness of a company is further improved. In addition, the detachable support facilitates later maintenance, the troubleshooting time is shortened, and the data storage module facilitates later analysis and summarization of equipment operation conditions.

Description

Technical Field

[0001] This invention relates to the field of dry screen cleaning equipment technology, specifically a real-time monitoring system for vacuum valves in dry screen cleaning. Background Technology

[0002] During the dry wire cleaning process, the proper functioning of the vacuum valve is crucial to the quality of the paper products. Currently, due to prolonged use, the valve slide plates of the dry wire cleaning vacuum valves have become rusted. Furthermore, during routine dry wire cleaning, adhesive residue easily adheres to the vacuum valve slide plates, causing frequent valve jamming and resulting in a lack of actual vacuum.

[0003] Meanwhile, although the dry wire cleaning was in operation, the vacuum was reduced and unstable because the previous set of vacuum valves was not closed. This resulted in ineffective control of water stains on the dry wire, causing dry wire marks to appear on the paper. Furthermore, there were instances where vacuum valves were not opened and were not detected in time, leading to a lack of vacuum. All these problems seriously affected the quality of the paper products.

[0004] In addition, the cost of retrofitting the 11 sets of vacuum transmitters for dry network cleaning is high, and without using the transmitters, the vacuum status cannot be detected in real time, which brings many inconveniences to production. Summary of the Invention

[0005] The purpose of this invention is to provide a real-time monitoring system for vacuum valves used in dry cleaning, in order to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a real-time monitoring system for vacuum valves in dry mesh cleaning, comprising a detection module, an alarm module, a feedback module, a program optimization module, a support structure, and a data storage module; The detection module uses a lower limit switch and a self-made fixing bracket to detect the real-time status of the vacuum valve; The alarm module issues an alarm signal when the vacuum valve malfunctions, based on the detection results from the detection module. The feedback module adds real-time vacuum valve feedback to the DCS screen, making it convenient for operators to view the vacuum valve status in real time. The program optimization module optimizes the dry net cleaning program and sets alarm conditions; The bracket structure is a self-made fixed bracket used to install the limiting component. Its relevant parameters include normally open limiting dimensions at different positions, including but not limited to 38CM, 26CM, 12CM, 14CM, and 70CM. It also uses M8 detachable screws for easy maintenance later. The data storage module is used to store the operating status data and alarm record information of the vacuum valve.

[0007] Preferably, the lower limit switch in the detection module is a reusable normally open lower limit proximity switch, combined with a self-made 304 stainless steel fixing bracket, to achieve real-time detection of the vacuum valve's switching status.

[0008] Preferably, the alarm conditions set by the program optimization module include: when there is no running signal for dry cleaning, but the vacuum valve remains open for 5 seconds, the alarm module will issue an alarm; when there is a running signal for dry cleaning, but the vacuum valve remains closed for 5 seconds, the alarm module will issue an alarm.

[0009] Preferably, the feedback module displays the vacuum valve feedback status (open or closed), actual vacuum pressure value, simulated value, high-pressure water outlet pressure, sewage cleaning valve operating status and timing information (such as cleaning for 1 minute every 60 minutes) on the DCS screen.

[0010] Preferably, the alarm signal emitted by the alarm module can be displayed on the DCS screen to remind operators to handle abnormal situations of the vacuum valve in a timely manner.

[0011] Preferably, the data storage module stores data including but not limited to vacuum valve on / off status records, vacuum pressure data, alarm records, and operational feedback information, which facilitates later querying and analysis.

[0012] The monitoring method of the real-time monitoring system for vacuum valves in dry mesh cleaning includes the following steps: Step 1, System Deployment and Initialization: Install the self-made fixed bracket and the normally open proximity switch at the bottom of the machine; connect the detection module, alarm module, and feedback module to the dry net cleaning system; initialize the program optimization module and set the alarm conditions and related parameters. Step 2, Real-time detection: The detection module uses a normally open proximity switch and a fixed bracket to detect the opening and closing status of the vacuum valve in real time, and transmits the detection data to the feedback module and the program optimization module. Step 3, Status Feedback: The feedback module displays the feedback status of the vacuum valve, the actual value of the vacuum pressure, the simulated value, the high-pressure water outlet pressure, the operating status of the sewage cleaning valve, and the timing information on the DCS screen in real time. Step 4, Alarm Judgment and Handling: The program optimization module judges the data transmitted by the detection module according to the set alarm conditions. When the alarm conditions are met, the module controls the alarm module to issue an alarm signal on the DCS screen. Step 5, Data Storage: The data storage module continuously stores the operating status data and alarm record information of the vacuum valve to ensure data traceability.

[0013] Compared with the prior art, the beneficial effects of the present invention are: This invention optimizes the dry wire cleaning process by utilizing a lower limit switch and a self-manufactured fixing bracket, achieving cost-free and efficient real-time monitoring of vacuum valve usage. This effectively prevents downgrading and dry wire printing issues caused by vacuum valve jamming, thus improving paper quality. Simultaneously, by adding real-time feedback and alarm functions to the DCS screen, vacuum valve malfunctions can be detected promptly, reducing the failure rate and workload, thereby enhancing the company's market competitiveness. Furthermore, the detachable bracket facilitates later maintenance, reduces troubleshooting time, and the data storage module allows for convenient analysis and summarization of equipment operation. Attached Figure Description

[0014] Figure 1 This is a system schematic diagram of the present invention; Figure 2 This is a system flowchart of the present invention; Figure 3 This is a structural diagram of the support structure of the present invention, where 1 represents vacuum and 2 represents the support structure; Figure 4 This is a circuit diagram for the detection of the vacuum valve for dry mesh cleaning in this invention. In the diagram, 1 is the vacuum valve, 2 is the support structure, 3 is the normally open limit switch, 4 is the vacuum box, 5 is the vacuum box terminal block, 6 is the 24V power supply, 7 is the PLC, and 8 is the cabinet terminal block. Detailed Implementation

[0015] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0016] Please see Figure 1-4 The present invention provides a real-time monitoring system for vacuum valves in dry cleaning, including a detection module, an alarm module, a feedback module, a program optimization module, a support structure, and a data storage module; The detection module uses the lower limit switch and a self-made fixing bracket to detect the real-time status of the vacuum valve; The alarm module issues an alarm signal when the vacuum valve malfunctions, based on the detection results from the detection module. The feedback module adds real-time vacuum valve feedback to the DCS screen, making it convenient for operators to view the vacuum valve status in real time. The program optimization module optimizes the dry screen cleaning program and sets alarm conditions; The bracket structure is a self-made fixed bracket used to install the limiting components. Its relevant parameters include normally open limiting dimensions at different positions, including but not limited to 38CM, 26CM, 12CM, 14CM, and 70CM. It also uses M8 detachable screws for easy maintenance later. The data storage module is used to store the operating status data and alarm record information of the vacuum valve.

[0017] The lower limit switch in the detection module uses a reusable normally open lower limit switch, combined with a self-made 304 stainless steel fixing bracket, to achieve real-time detection of the vacuum valve's on / off status.

[0018] The alarm conditions set by the program optimization module include: when there is no operation signal for dry cleaning, but the vacuum valve remains open for 5 seconds, the alarm module will issue an alarm; when there is an operation signal for dry cleaning, but the vacuum valve remains closed for 5 seconds, the alarm module will issue an alarm.

[0019] The feedback module displays the vacuum valve feedback status (open or closed), actual vacuum pressure value, simulated value, high-pressure water outlet pressure, sewage cleaning valve operating status, and timing information (such as cleaning for 1 minute every 60 minutes) on the DCS screen.

[0020] The alarm signal emitted by the alarm module can be displayed on the DCS screen, reminding operators to deal with abnormal vacuum valve conditions in a timely manner.

[0021] The data storage module stores data including but not limited to vacuum valve on / off status records, vacuum pressure data, alarm records, and operational feedback information, which facilitates later querying and analysis.

[0022] The monitoring method of the real-time monitoring system for vacuum valves in dry mesh cleaning includes the following steps: Step 1, System Deployment and Initialization: Install the self-made fixed bracket and the normally open proximity switch at the bottom of the machine; connect the detection module, alarm module, and feedback module to the dry net cleaning system; initialize the program optimization module and set the alarm conditions and related parameters. Step 2, Real-time detection: The detection module uses a normally open proximity switch and a fixed bracket to detect the opening and closing status of the vacuum valve in real time, and transmits the detection data to the feedback module and the program optimization module. Step 3, Status Feedback: The feedback module displays the feedback status of the vacuum valve, the actual value of the vacuum pressure, the simulated value, the high-pressure water outlet pressure, the operating status of the sewage cleaning valve, and the timing information on the DCS screen in real time. Step 4, Alarm Judgment and Handling: The program optimization module judges the data transmitted by the detection module according to the set alarm conditions. When the alarm conditions are met, the module controls the alarm module to issue an alarm signal on the DCS screen. Step 5, Data Storage: The data storage module continuously stores the operating status data and alarm record information of the vacuum valve to ensure data traceability.

[0023] Example 1: Taking a dry screen cleaning production line as an example, the real-time monitoring system and method for the vacuum valve of the dry screen cleaning of the present invention will be specifically described as follows: The production line is equipped with self-made 304 stainless steel fixed brackets. The normally open limit dimensions on the brackets are 38CM, 26CM, 12CM, 14CM and 70CM respectively. They are fixed with M8 detachable screws and the normally open proximity switches from the off-machine are reused as detection elements.

[0024] During system initialization, alarm conditions are set through the program optimization module: when there is no operating signal for dry cleaning, but the vacuum valve remains open for 5 seconds, an alarm will be triggered; when there is an operating signal for dry cleaning, but the vacuum valve remains closed for 5 seconds, an alarm will be triggered.

[0025] The detection module uses normally open proximity switches to detect the on / off status of each group of vacuum valves in real time, such as the status of the first group, the second group, the third group, the lower third group, and the upper seventh group, and transmits the detection data to the feedback module and the program optimization module.

[0026] The feedback module displays the vacuum valve's open or closed status in real time on the DCS screen, the actual vacuum pressure values ​​such as -27KPa, -28KPa, -29KPa, etc., the high-pressure water outlet pressure such as 501.3bar, 521.6bar, 524.8bar, etc., and the sewage cleaning valve's operating status as running, with a timer setting of 1 minute of cleaning every 60 minutes.

[0027] When the program optimization module determines that the alarm conditions are met, the alarm module issues an alarm signal on the DCS screen. For example, if there is no operating signal for dry cleaning, and the third set of vacuum valves is open for 5 seconds, the DCS screen will display an alarm for all three sets of vacuum valves.

[0028] Upon seeing the alarm signal, operators can promptly address any abnormalities in the vacuum valve. The data storage module stores information such as the vacuum valve's on / off status, vacuum pressure data, and alarm records throughout the entire process, facilitating later retrieval and analysis.

[0029] In summary, this invention, through cost-free modification and optimization, achieves real-time monitoring of the dry wire cleaning vacuum valve, effectively improving paper quality and reducing the failure rate, and has significant application value.

[0030] Example 2: See Figure 4Multiple vacuum valves 1 are installed inside the vacuum chamber 4 via a bracket structure 2. A normally open limit switch 3 is installed at the connection between the vacuum valve 1 and the bracket structure 2. The vacuum valve 1 is connected to the vacuum chamber terminal 5 installed inside the vacuum chamber 4 via a wire. The vacuum chamber terminal 5 is connected to the cabinet terminal 8 via a wire. The cabinet terminal 8 is connected to the 24V power supply 6 and the PLC 7 via wires respectively. The PLC 7 is connected to the 24V power supply 6 via a wire.

[0031] This invention optimizes the dry wire cleaning process by utilizing a lower limit switch and a self-manufactured fixing bracket, achieving cost-free and efficient real-time monitoring of vacuum valve usage. This effectively prevents downgrading and dry wire printing issues caused by vacuum valve jamming, thus improving paper quality. Simultaneously, by adding real-time feedback and alarm functions to the DCS screen, vacuum valve malfunctions can be detected promptly, reducing the failure rate and workload, thereby enhancing the company's market competitiveness. Furthermore, the detachable bracket facilitates later maintenance, reduces troubleshooting time, and the data storage module allows for convenient analysis and summarization of equipment operation.

[0032] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A real-time monitoring system for vacuum valves in dry mesh cleaning, characterized in that: It includes a detection module, an alarm module, a feedback module, a program optimization module, a support structure, and a data storage module; The detection module uses a lower limit switch and a self-made fixing bracket to detect the real-time status of the vacuum valve; The alarm module issues an alarm signal when the vacuum valve malfunctions, based on the detection results from the detection module. The feedback module adds real-time vacuum valve feedback to the DCS screen, making it convenient for operators to view the vacuum valve status in real time. The program optimization module optimizes the dry net cleaning program and sets alarm conditions; The bracket structure is a self-made fixed bracket used to install the limiting component. Its relevant parameters include normally open limiting dimensions at different positions, including but not limited to 38CM, 26CM, 12CM, 14CM, and 70CM. It also uses M8 detachable screws for easy maintenance later. The data storage module is used to store the operating status data and alarm record information of the vacuum valve.

2. The real-time monitoring system for the vacuum valve of the dry cleaning system according to claim 1, characterized in that: The lower limit switch in the detection module uses a reusable normally open lower limit switch, combined with a self-made 304 stainless steel fixing bracket, to achieve real-time detection of the vacuum valve's switching status.

3. The real-time monitoring system for the vacuum valve of the dry mesh cleaning system according to claim 1, characterized in that: The alarm conditions set by the program optimization module include: when there is no operation signal for dry cleaning, but the vacuum valve remains open for 5 seconds, the alarm module will issue an alarm; when there is an operation signal for dry cleaning, but the vacuum valve remains closed for 5 seconds, the alarm module will issue an alarm.

4. The real-time monitoring system for the vacuum valve of the dry cleaning system according to claim 1, characterized in that: The feedback module displays the vacuum valve feedback status, actual vacuum pressure value, simulated value, high-pressure water outlet pressure, sewage cleaning valve operating status, and timing information on the DCS screen.

5. The real-time monitoring system for the vacuum valve of the dry mesh cleaning system according to claim 1, characterized in that: The alarm signal emitted by the alarm module can be displayed on the DCS screen, reminding operators to deal with abnormal vacuum valve conditions in a timely manner.

6. The real-time monitoring system for the vacuum valve of the dry cleaning system according to claim 1, characterized in that: The data storage module stores data including, but not limited to, vacuum valve on / off status records, vacuum pressure data, alarm records, and operational feedback information, which facilitates later querying and analysis.

7. The monitoring method of the real-time monitoring system for the vacuum valve of the dry network cleaning system according to any one of claims 1-6, characterized in that: Includes the following steps: Step 1, System Deployment and Initialization: Install the self-made fixed bracket and the normally open proximity switch at the bottom of the machine; connect the detection module, alarm module, and feedback module to the dry net cleaning system; initialize the program optimization module and set the alarm conditions and related parameters. Step 2, Real-time detection: The detection module uses a normally open proximity switch and a fixed bracket to detect the opening and closing status of the vacuum valve in real time, and transmits the detection data to the feedback module and the program optimization module. Step 3, Status Feedback: The feedback module displays the feedback status of the vacuum valve, the actual value of the vacuum pressure, the simulated value, the high-pressure water outlet pressure, the operating status of the sewage cleaning valve, and the timing information on the DCS screen in real time. Step 4, Alarm Judgment and Handling: The program optimization module judges the data transmitted by the detection module according to the set alarm conditions. When the alarm conditions are met, the module controls the alarm module to issue an alarm signal on the DCS screen. Step 5, Data Storage: The data storage module continuously stores the operating status data and alarm record information of the vacuum valve to ensure data traceability.

Images